A hybrid production planning approach for waste minimisation in convenience food manufacture

This thesis reports on the research undertaken to minimise wastes from overproduction that are created to meet demanding due dates imposed by retailers in convenience food manufacture. The principle objective of this research is to generate knowledge and generic solutions to minimise the environmental impacts of such wastes through effective production planning and improved processing and supply chain practices. The research contribution is divided into three major parts. The first part reviews the most relevant publications and legislation, and categorises the contemporary techniques in supply chain management, operations management and production planning. The second part is concerned with three novel concepts of (a) identifying, modelling and analysing the various types of wastes in food industry (b) the systematic support for the improvement of production and supply chain activities through generation of a Responsive Demand Management framework, and (c) the realisation of a hybrid two stage planning approach for minimisation of overproduction wastes. The final part demonstrates the application of these research concepts through a case study for minimisation of overproduction waste within a ready-meal manufacturer. The hybrid two stage planning approach has been shown to be an effective method by which overproduction wastes can be addressed for products with production lead-times that exceed order lead-times. The responsive demand management framework is a powerful method for the identification and recording of production and supply chain inefficiencies that can be utilised to establish a programme of improvements for further waste reduction. Classification, modelling and analysis of food industry wastes by this research has provided food manufacturing with significant tools to monitor and reduce environmental impacts. The case study has effectively demonstrated the applicability of the research concepts in significantly reducing overproduction waste. In summary, this research has highlighted the environmental and economic impacts of waste and has underpinned the paramount importance of establishing sustainable manufacturing and supply chain procedures in convenience food sectors.